Magnetic fastener clip

ABSTRACT

A magnetic fastener clip includes a cup having at least one hole, an overmold is attached to the cup and a magnet. The overmold has: a cup cover is injection molded on an outside portion of the cup, and an inner ring is injection molded on at least part of an inside portion of the cup. The inner ring is attached to the cup cover via the at least one hole. The magnet operably attaches into the inner ring. According to one embodiment, a turn coupler attaches to the cup cover. The magnetic fastener clip is operative for blind attachment into a structure, such as a vehicle chassis i.e. a pillar, door frame, chassis or roof.

RELATED APPLICATIONS

This application claims benefit of provisional 62/299,597, entitledMagnetic Fastener Clip, and having a filing date of Feb. 25, 2016. Thisapplication is a continuation in part application claiming priority froman application entitled “Magnetic Fastener Clip” having a Ser. No.14/622,893, and having a filing date of Feb. 15, 2015, which is acontinuation in part application claiming priority from an applicationentitled “Magnetic Fastener Clip” having a Ser. No. 13/831,525, andhaving a filing date of Mar. 14, 2013, which is a continuation in partapplication claiming priority from an application entitled “MagneticFastener Clip” having an application Ser. No. 12/983,010 and a U.S. Pat.No. 8,287,034 with a filing date of Dec. 31, 2010, and a patent issuedate of Oct. 16, 2012, which is a continuation in part applicationclaiming priority from an application entitled “Magnetic Fastener Clip”having an application Ser. No. 12/464,867 and a U.S. Pat. No. 8,615,852,with a filing date of May 13, 2009, and a patent issue date of Dec. 31,2013, the entire disclosure of which is incorporated herein byreference.

FIELD OF THE INVENTION

The invention relates generally to devices for fastening objects, andmore particularly to a magnetic fastener clip for insertion into anengagement structure, such as a vehicle chassis, a hollow substrate, awall, a plate or any suitable surface.

BACKGROUND OF THE INVENTION

A number of devices and fasteners are currently available for fasteningpanels such as body panels and automobile interior trimpiece panels tothe chassis of a vehicle. Fastener clips are used in automobileassemblies to secure body panels such as pillar covers, headliners,interior panels and the like to chassis structures such as roofs, doorstructures and body pillars. As used herein, a body panel refers to, forexample, any interior or exterior structure attached to a vehicle, suchas a plastic or metal interior trim piece or any interior trimpiece. Thebody panel may be any suitable exterior body panel, such as a fender,bumper, quarter panel or door panel. The chassis of the vehicle mayinclude any substrate, plate, body panel, structural framework, chassiscomponent or subcomponent, support component, wall or any suitableobject or combination.

Interior automobile fasteners, such as screws, are known to retain abody panel to a vehicle chassis. For example, a screw may attach aheadliner in position within the automobile roof. However, many of thesefasteners may only fasten around the periphery of a headliner. While adome light or the like may be located in the middle of the roof area,extensive expanses of the headliner are not supported or fastened bysuch structures. However if the middle of a body panel is attached by afastener, then the periphery are not supported. As a result, thesefasteners allow the body panel such as the headliner to sag, providingan aesthetically unacceptable appearance.

Attaching the headliner to the interior of the roof typically requiressecuring clips already fastened to a headliner assembly into a hole,slot or mounting point on the roof. At least some of the clips requireblind insertion and installation of the fasteners because the installeris not able to view the fastener clip or the mounting point on the roof.

Fastener clips are also known for attaching body panels to an automobilechassis. For example, fastener clips are known that attach to anautomobile headliner or the like using adhesive, and which connects to amagnet. Magnets may be used to reduce the problem of the blind fastenerapplication. Thus, magnetic fastening clips may automatically positionthe body panel and thus do not require as much alignment between afastener and a mating hole.

Another known clip has a base, a dome spaced from the base and aplurality of supports between the base and the dome. A hollow postextends outwardly from the dome and includes at least one deflectableportion having an outward protuberance thereon. A pin is substantiallyaligned with the post and connected thereto by at least one frangiblelink. A frangible link between the pin and the clip is adapted torupture when the pin is driven. However, since the pin requiresalignment and insertion during manufacture, assembly is time consuminglabor intensive and expensive. Further, the assembly of the magnet tothe fastener typically requires a hole drilled into the magnet in orderto attach the magnet to the fastener via a pin, screw or other fastenerto go through the hole. The hole reduces the amount of magnetic flux andthus reduces the magnetic strength, requires additional processing stepsand increases costs.

These known clips however are neither sufficiently rugged nor flexiblefor example on an automobile assembly line that can be somewhat harsh.During installation the headliner can be moved, stretched or twistedinconsistently. These fastening clips typically do not have a longuseful life to support the headliner and prevent staking throughout theanticipated life expectancy of the vehicle. Also, these fastening clipshave a fixed engagement length between the chassis and body panel.

The fastener device is typically required to secure the panel to thechassis that may have sheet metal with different amounts of curvature orthicknesses throughout. If the sheet metal varies in curvature orthickness or if for example, tolerances in production occur in thevehicle chassis or in the trim-piece, i.e. headliner, then engagement ofone fastener to the roof may not provide suitable magnetic engagement ormay otherwise result in movement. Further, less than all these fastenerstypically make engagement with the chassis. Twisting of the body panelwill be likely more prevalent because less than all contact points areactually made with the roof. As a result, sagging, wear, squeaks,rattles, buzzing, corrosion and loss of elasticity and loss of sealingmay result, especially after years of vehicle operation and exposure tovibration and other environmental conditions. As such, these fastenerclips do not provide suitable magnetic engagement or sufficientflexibility.

Once installed, during use of the automobile, the headliner is sometimescontacted or pushed by passengers. The fastener device typically securesthe headliner under a variety of environmental conditions, such as inthe presence of vibration at various levels of amplitude and frequency.Further, the fastener device should prevent or minimize the amount ofbuzzing, rattling or any other type of noise that may cause attention tothe occupants of the vehicle or otherwise weaken the attachment. Furtheryet, fasteners seek the conflicting goal of securing a body panel to thechassis while accommodating various levels of sheet metal curvature,thicknesses, and production tolerances. For example tolerances, such asvarious dimensions amongst the body panels as well as the vehiclechassis may be accommodated. Conventional fastener devices typically donot adequately fasten to a range of sheet metal thicknesses and do notminimize or eliminate buzzing and rattling and do not sufficientlyaccommodate variations in production tolerances. As a result, theseclips do not properly fasten the body panel to the chassis. If thefastener clip is broken after installation of the body panel, saggingcan occur again presenting the aesthetically undesirable appearance.Further, replacement of an installed, broken clip can be difficult.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a magnetic fastener clip and body panel assemblyaccording to one embodiment;

FIG. 2 is an exploded view of a magnetic fastener clip and body panelassembly according to another embodiment;

FIG. 3 is an exploded view of a magnetic fastener clip according toanother embodiment;

FIG. 4 is a perspective view of the magnetic fastener clip according toone embodiment;

FIG. 5 is a side cut away view of the magnetic fastener clip accordingto one embodiment;

FIG. 6 is a bottom perspective view of the magnetic fastener clipaccording to one embodiment;

FIG. 7 is a side view of the magnetic fastener clip according to oneembodiment;

FIG. 8 is a top view of the magnetic fastener clip according to yetanother alternative embodiment;

FIG. 9 is a bottom view of the magnetic fastener clip in an unlockedposition;

FIG. 10 is a bottom view of the magnetic fastener clip in a rotatedposition;

FIG. 11 is a bottom view of a magnetic fastener clip in a lockedposition;

FIG. 12 is a top view of a portion of the overmold and cup according toan embodiment; and

FIG. 13 is a magnetic fastener according to another embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A magnetic fastener clip includes a cup having at least one hole, anovermold is attached to the cup and a magnet. The overmold has: a cupcover is injection molded on an outside portion of the cup, and an innerring is injection molded on at least part of an inside portion of thecup. The inner ring is attached to the cup cover via the at least onehole. The magnet operably attaches into the inner ring. According to oneembodiment, a turn coupler attaches to the cup cover. The magneticfastener clip is operative for blind attachment into a structure, suchas a vehicle chassis i.e. a pillar, door frame, chassis or roof.

Among other advantages, the magnet does not require a hole in the magnetto attach to the cup. Since the magnet is not drilled to create a hole,the magnet does not suffer from a reduction of magnetic flux. Thus, themagnet retains the high level of magnetic flux and thus the magneticforce is maximized. Also, since the steps of drilling the magnet holeand fastening via the magnet hole is not required, attachment of themagnet to the cup is significantly reduced, cost is reduced andmanufacturing time is reduced.

Another significant advantage is that the magnetic fastener clipincluding the cup may be manufactured with few stamping and overmoldingsteps. According to one embodiment, the cup is stamped in one or a fewnumber of pressing steps. For example, the cup may be made withoutexpensive milling, cutting or drilling and is thus ready for overmoldingdirectly after stamping. According to one embodiment, the cup may bemade with a single stamping step, with a recess around the ring of thecup to permit a burr to form due to stamping. The recess accommodatesthe formation of the burr during stamping and thus does not interferewith the cup edge. As a result, the cup edge remains uniform and evenlyengages the chassis plane. The recess avoids the need for filing theburr.

According to yet another advantage, the overmold step directly forms thecup cover and the inner rings in one injection process. The magneticfastener is relatively easy to manufacture using relatively inexpensivemanufacturing processes and materials, especially compared to knownmanufacturing processes. The use of the magnetic fastener clip decreasesproduction costs, increases worker productivity and efficiency, improvesreliability and quality and decreases overall vehicle assembly, warrantyand maintenance costs.

The optional coupler is operative to flex or compress according to anappropriate curvature. As the coupler flexes, the magnetic fastener maypivot about the coupler boss for example at an angle to allow themagnetic fastener to adapt to different surface curvatures whilesecurely fastened to the body panel. Thus, the coupler and/or bossstructure adapts to different attachment lengths, variations of sheetmetal roundness and thicknesses thus allowing the magnet fastener toadjust to different depths while pivoting and maintaining a high levelof extraction force. During installation, the magnet continuously adaptsto variations in curvature and dimensions of the vehicle roof and/or inthe body or headliner panel. Thus, only a single magnetic fastener clipneed be used with a vehicle or application even if different attachmentpoints or even if the curvature or thickness of the sheet metal variessubstantially.

Yet another advantage of the magnet, along with an optional coupler,permits relatively easy insertion of the magnetic fastener clip into avehicle chassis, pillar, instrument panel structure, door, roof orsuitable body panel while providing a relatively high level ofextraction force from the body panel. Assembly of the body panel ontothe vehicle chassis is very easy and requires no or a relatively lowlevel of insertion force compared to the extraction force, and as aresult provides many ergonomic advantages. For example, the relativelylow level of insertion force is particularly advantageous for assemblyline operators who repetitively insert body panels onto the vehiclechassis. The relatively low level of insertion force required forblindly inserting the body panel into the vehicle chassis may result infewer injuries to the assembly workers, including injuries related torepetitive stress syndrome. Further by selecting a single fastener orreducing the number of different fasteners for different sheet metalcurvatures and thicknesses, confusion during assembly is eliminatedsince the same type or a reduced number of fasteners may be used for allor most body panel fasteners. Thus, an assembly worker need not worryabout selecting the wrong fastener.

The magnetic fastener clip relatively easily facilitates attachment of abody panel with the structure, such as the vehicle door frame, chassis,instrument panel structure, pillar or roof, such that a singleadjustable magnetic fastener clip may be used with different depthattachment requirements, sheet metal curvatures and/or thicknesses. Forexample, a vehicle door, pillar, instrument panel structure, chassis, orroof may have different sheet metal curvatures and attachment points atvarious parts of the vehicle. The body panel may be an automobileheadliner, door panel, instrument panel, an A, B, C, D, etc. pillarpanel, bumper, fender, quarter panel, grill, hood, roof, trunk panel orany suitable interior or exterior panel.

The relatively high level of extraction force, characteristic of themagnetic fastener clip, securely attaches the body panel, such as a doorpanel, or headliner, to the vehicle chassis. Further, the fastener clipcontinuously adapts to changes in environmental conditions such asvehicle flexing, pushing by passengers, vibration and thermal expansion.For example, the magnetic fastener clip may adapt to changes in thermalexpansion, especially due to the differences in thermal expansion ratesbetween dissimilar metals with respect to the vehicle chassis componentsand/or between plastic components such as the interior trim panelsattached to the metal vehicle chassis. The fastener clip may also fastento plastic and/or metal engagement structures. The fastener clip may bemade of anti-corrosive material such as plastic or treated metal toprovide long reliable service life.

The magnetic fastener clip securely attaches a body panel such as a doorpanel to a door frame, or headliner to the vehicle roof, such that themagnetic fastener clip installs easily, fastens securely, improvesreliability both in the short term and in the long term, while furtherimproving vehicle safety and quality.

FIGS. 1, 2 and 3 are perspective views of a magnetic fastener clip 10according to an embodiment. The magnetic fastener clip 10 includes a cup20 having at least one hole 30, a magnet 40, and an overmold 50 attachedto the cup 20. The overmold 50 has: a cup cover 60 attached to anoutside portion of the cup 20, and an inner ring 70 attached to aninside portion of the cup 20 and an optional coupler 90. The inner ring70 may be attached to the cup cover 60 via the at least one hole 30. Themagnet 40 operably attaches into the inner ring 70, such as via glue,press fit or any suitable attachment. According to one embodiment, thecup cover 60 and the inner ring 70 are injection molded over at leastone part of the cup 20 to form the inner ring 70 and the cup cover 60.The magnetic fastener clip 10 is operative for blind attachment into astructure 80, such as a vehicle chassis i.e. door frame, chassis orroof.

As shown in FIGS. 3-7, an optional coupler 90 is attached to the cupcover 60. According to one embodiment, the coupler 90 is operative toflex. For example, cup cover 60 may be or may include an optionalcoupler 90 suitable to engage a mounting structure 100 (shown in FIGS. 1and 2). The coupler 90 of the magnetic fastener 10 clip adapts todifferent surface curvatures and thicknesses.

As shown but not limited to FIGS. 5 and 7, optional coupler 90 mayfurther include wing 22 and key way base 24 connected by a post 600, anda boss 610 attaching the wing 22 and key way base 24 with the cup cover60. Wing 22, key way base 24 and post 600 may be sized to suitablyengage a panel mounted tower 110 with a side-slot 200 in a body panel100 such as a headliner, interior cover, pillar cover, panel over or anyobject suitable for magnetic fastening to chassis 80.

The wings 22 and key way base 24 may be keyed or designed in anysuitable shape such as square, oval, round, rectangular or as shown inFIG. 2. For example, the key way base 24 may resemble a key hole suchthat the key way base 24 is inserted into a correspondingly shaped slot200 in body panel 100 or tower 110.

FIG. 9 is a bottom view of the body panel 100 in an unlocked positionwhere the key way base 24 is inserted in the correspondingly shaped slot200 in body panel 100.

FIG. 10 is a bottom view showing the key way base 24 during rotation.The wing 22 and key way base 24 may have any suitable size and relativespacing between wing 22 and key way base 24 via post 600. For example,as they key way base 24 rotates about the post 600 in the slot 200, thekey way base 24 ends and the wings 22 squeeze the body panel 100,110 tostabilize the magnetic fastener 10.

FIG. 11 is a bottom view showing the key way base 24 in a lockedposition. The locking tabs 72 on the at least one wing 22 cause the wing22 and key way base 24 to spring and cause compression on the body panel100,110. This compression reduces rotation from the locked position andfurther stabilizes the magnetic fastener from rocking side to side whilein the slot 200. Among other advantages, the magnetic fastener 10 iseasily serviced by reversing the rotation of the key way base 24 untilaligned with the slot 200 to permit removal of the magnetic fastener 10.

As shown in FIGS. 7 and 8 the wings 22 and in particular the wing endsmay be curved. Among other advantages, the curved wings 22 are easier toinjection mold, allow for more efficient packaging space since thecorners 22 shown in FIG. 8 are reduced, and facilitate manipulation andthus the magnetic fastener 10 is easier to grip.

According to the embodiment shown in FIGS. 3-7, the wings 22 may beangled. The shape of the wings may be suitable for the application andenvironment.

Alternatively, optional coupler 90 may include any attachment mechanismsuitable to couple or attach to a body panel 100, 110 such as a nut,bolt, weld stud, thread stud, button head, clip, panel clip, retainer,panel mounted receptacle, retainer washer, or rivet, cable tie, wireclip, hook and loop fastener (Velcro®)), sticky tape, double faced tape,glue, spike array, or any suitable combination. The correspondingmounting structure 90 thus would attach to the base attachment mechanism110 on body panel 100 such as a u-shaped compression flange to engagethe post 600 and wing 22 and key way base 24, a bolt-nut, or anysuitable fastener pair.

As shown in FIG. 1, the overmold 50 may be manufactured by forming thecup cover 60 and the inner ring 70 by injection molding over at leastone part of the cup 20 to form the inner ring 70 and the cup cover 60.The inner ring 70 may be formed by temporarily inserting a core pininside the cup such that as the heated and liquefied plastic isinjected, the plastic forms the inner ring 70 and the inside of the cup20. The core pin diameter may be sized such that the diameter of theinner ring 70 permits the corresponding diameter of the magnet 40 to besuitably press fit into the inner ring 70. For example, the core pindiameter may be sized smaller than the diameter of the magnet 40, suchthat the magnet 40 may be securely press fit into the cup 20.Accordingly, the plastic molded inner ring 70 may elastically compressbetween the magnet 40 and the cup 20 to firmly secure the magnet 40 inthe cup 20. According to an alternative embodiment, the magnet 40 may besecured to the cup 20 via, glue, pin, screw, nut, rivet, adhesive or anysuitable fastener.

As shown in FIG. 5, the thickness of inner ring, gap 62 is sizedappropriately to permit bending of the magnetic flux from both magneticpoles toward the chassis 80. In order to maximize the magnetic flux andthus the magnetic force, the cup 20 may have the gap 62 between theinside of the cup 20 and the magnet 40 sized to maximize magnetic fluxlines to flow from the cup side to the chassis 80. For example, theinner ring 70 may have a diameter thickness 62 such that the magneticflux from the cup side 22 20 of the magnet 40 flows to the metal chassis80. As a result, the magnetic flux of both sides and both poles of themagnet 40 create magnetic forces attracting the metal chassis 80. Thecombination of magnetic flux from both sides or poles of the magnet 40creates a greater magnetic force than from just one side or pole of themagnet 40. Although the gap 62 is formed from the inner ring 70 as shownin the figures, the gap 62 may be air, part plastic and air, glass,rubber or any suitable material or combination. Alternatively, the innerring 70 and thus the gap 62 may be or include aluminum, titanium,magnesium, or any other suitable metal or material to allow the magneticflux to flow from the cup side 22 20 to the metal chassis 80.

According to one embodiment, the inner ring 70 is sized in order tolocate the magnet 40 in the cup 20 at a predetermined distance from theinner surface of the cup 20. For example, as the magnet 40 is pressedinto the inner ring 70, the inner ring 70 positions and locates themagnet 40 appropriately in order to direct magnetic flux to flow fromthe cup side 22 to the metal chassis 80 and to securely hold the magnet40. According to another embodiment, the magnet 40 is removable andreinstallable from the cup 20 to permit servicing for example.

According to one embodiment, the magnet 40 does not contact the magneticattachment surface 80. Instead, the magnet 40 is positioned at anattachment distance between the magnet 40 and the magnetic attachmentsurface 80 in order to maximize magnetic flux on the magnet bottom toflow to the top and thus maximize the magnetic attachment force. Asshown in FIG. 5, according to one embodiment, the magnet 40 is adistance 530 from and thus never touches the magnetic attachment surface80. For example, the magnet 40 sits 0.1 mm or any suitable distancebelow sheet metal or contact surface 80. The distance 530 is may bedetermined to provide the maximum magnetic flux and thus magnetic force.A distance 530 that is non-zero may provide more magnetic flux thanzero.

As shown in FIGS. 2 and 3, at least one hole 30 allows injection moldingof the inner ring 70. For example, melted plastic is injection moldedaround cup 20 causing melted plastic to flow through holes 30 in cup 20.Melted plastic flows inside cup 20 and around core pin to form the innerring 70. The number and the arrangement of the holes 30 may be selectedto suitably permit melted plastic to completely and to thoroughly fillthe mold forming inner ring 70 between the cup 20 and the core pin.

As best shown in FIG. 12 according to one embodiment, the cup 20 has arecess 500 and optional ring 520 around an outside perimeter of the cup20 sized to avoid stamping burrs (not shown) from contacting a magneticattachment surface. For example, the recess 500 and outer ring 520 ofcup 20 may be formed by stamping the cup 20 to form the recess 520 adistance 510 below the cup edge. The burr is caused by a stamping of thecup 20. Alternatively, a burr trimmer or lathe may make a top recess 520on the cup 20 to have a uniform surface. However, the processes of burrtrimming or lathe trimming are more process intensive. Rather than theburr trimming or lathe trimming, during stamping of the cup 20, a recess500 may be formed in the same process that the cup 20 and holes 30 areformed. The recess 500 may be formed so that the magnetic cup lip isflush with the magnetic attachment surface 80. For example, the burrheight is typically 4 thousandths of an inch, and thus the height of therecess 500 may be greater than 4 thousandths of an inch.

The inner ring 70 and the cup cover 60 may be made of plastic, metal orany suitable material or as described below. Although some examples ofthe inner ring 70 and the cup cover 60 are described and shown andfurther described below, including adjustable type fasteners, anysuitable material may be employed. By way of example, inner ring 70attaches to the cup cover 60 as an injection molded piece oralternatively via two pieces by: micro welding, ultrasonic welding (anultrasonic horn melts the plastic boss in a pre-determine location toattach the inner ring 70 and to the cup cover 60), heat welding, springfinger, screw and pin or any suitable combination thereof.

Although the fastener clip 10 is shown in FIGS. 1-8 with a round magnet40 any suitable shape may be used including oval, square, rectangular,triangular or polygon.

As shown in FIGS. 2, 5, 6 and 7, the coupler 90 is operative to flex orcompress about boss 610 and/or post 600 to permit the fastener clip 10to pivot. The boss 610 and/or post 600 permits the magnetic fastener toengage a magnetic surface or according to a curvature of an automobilebody panel. Any suitable combination of parameters may be sized topermit the desired amount of pivoting, flexing and or compressionaccording for example to the curvature of an automobile body panel suchas the roof.

Thus a body panel assembly 100 may include magnetic fasteners 10 ofvarious heights. For example the magnetic fasteners 10 of variousheights may be used where the distance between the headliner and roofvaries. As shown in FIG. 14, the height of the body panel 100/110, suchas is the case in a roof panel is relatively thin. Alternatively, thebody panel 100 shown in FIGS. 1 and 2 show a tower of appropriateheight.

The magnetic fastener clip 10 may replace one or more conventionalfasteners that would be inserted into the hole or slot of the bodypanel. Instead of requiring different conventional fasteners fordifferent size and height requirements, the magnetic fastener 10 maymagnetically attach to a chassis or the metal ring surrounding the slotin the body panel and adjust to different size and height requirements.

The coupler 90, wings 22, and key way base 24 may have any suitable sizeand relative spacing between wings 22, key way base 24 via post 600 orany suitable combination thereof may be sized to provide the appropriateflexing and spacing between the body panel, such as a headliner and thechassis such as the roof.

FIG. 1 is a perspective view of the body panel assembly 100. The bodypanel assembly 100 may be pre-assembled by attaching the post 600 of themagnetic fastener clip 10 to a body panel 100 as described above, suchas a pillar cover, headliner, or other suitable body panel to form abody panel assembly. Alternatively, the coupler 90 according to oneembodiment may instead comprise base holes (500 shown in FIG. 5 ofpending application Ser. No. 12/464,867 incorporated by reference). Thebase holes (500) permit attachment to the body panel by applying glue orany suitable fastener. Tapered holes that have a larger diameter on thetop side of the base (closest to the magnetic fastener 50 than on thebottom side (mating with the body panel) filled with glue will furtherprovide a mechanical connection as well as the chemical connection as aresult of the adhesive properties of the glue. The body panel assembly100 thus comprises a body panel 100 attached to the magnetic fastenerclip 10 attached to tower 110 via coupler 90, glue or other suitablefastener such as a screw, bolt, rivet or any suitable fastener to attachthe body panel to the magnetic fastener clip 10.

The body panel assembly 100 is operatively inserted as a single unitinto a structure, such as a vehicle chassis 80, pillar, roof, instrumentpanel or frame to form a vehicle with the magnetic clip. The magneticfastener clip 10 adapts to different chassis curvatures such that anangle between the magnetic fastener 10 and the coupler 90 is operativeto vary continuously. As previously stated, the coupler 90 may fasten toa body panel, frame or any suitable structure via a suitable fastener.

According to one embodiment, the overmold 50 is injection molded as asingle plastic component, thought multiple components may be assembledin one or more injection steps. The angle or inclination, sharpness ofcup cover 60 and inner ring 70 may vary depending on the diameter andshape of a slot in the vehicle chassis. Thus it is evident to oneskilled in the art that the suitable fastener 10 is shown and describedas yet another embodiment to illustrate that the structure for fasteningthe magnetic fastener 10 is not limited to the examples provided.

According to one embodiment, the cup 20 is made in whole or in part of:magnetic steel or any suitable metal or alternatively of plastic asdescribed below. The tower 110 and body panel 100 may be constructedfrom plastic or from any suitable material such as plastic, vinyl,cloth, wood, steel, aluminum, magnesium, carbon fiber or any suitablematerial.

The overmold 50, cup cover 60 and inner ring 70, cup 20 or anycombination of components may be made from: Polypropylene, glass fill,acetal, plastic, vinyl, rubber, plastisol, plastic, acetal, polyacetal,polyoxymethylene, nylon, fiberglass and carbon fiber and Acrylonitrilebutadiene styrene (ABS), or any suitable material and combinationthereof.

According to one embodiment, the wing 22, key way base 24, boss 610 andpost 600 are made of rubber, plastic, metal or any material that isflexible enough to support the overmold 50 and allow the magneticfastener 10 to flex. Wing 22, key way base 24, boss 610 and post 600 aremade from Polypropylene as described in co-pending application Ser. No.12/464,867 incorporated by reference. Polypropylene or polypropene isnormally tough and flexible, especially when copolymerised withethylene. This allows polypropylene to be used as an engineeringplastic, and thus may be used in place of other materials such as ABS,acrylic or certain other plastics. Polypropylene is reasonablyeconomical, and has good resistance to fatigue. Polypropylene has amelting point of ˜160° C. (320° F.), as determined by Differentialscanning calorimetry (DSC) and thus is suitable for injection molding.Melt processing of polypropylene can be achieved via extrusion andmolding. Injection molding may be used to obtain the desired shape.

It is understood that the implementation of other variations andmodifications of the present invention in its various aspects will beapparent to those of ordinary skill in the art and that the invention isnot limited by the specific embodiments described. It is thereforecontemplated to cover by the present invention any and allmodifications, variations or equivalents that fall within the spirit andscope of the basic underlying principles disclosed and claimed herein.

What is claimed is:
 1. A magnetic fastener clip comprising: a cup havingat least one hole; a cup cover injection molded on an outside portion ofthe cup; an inner ring injection molded on at least part of an insideportion of the cup; a turn coupler including a key way base attached tothe cup cover; and a magnet operably attached to the inner ring.
 2. Themagnetic fastener clip of claim 1 wherein the inner ring is injectionmolded via the at least one hole on at least part of the inside portionof the cup.
 3. The magnetic fastener clip of claim 1 wherein the innerring locates the magnet in the cup at a predetermined distance from theinner surface of the cup.
 4. The magnetic fastener clip of claim 1wherein the at least one hole allows injection molding of the innerring.
 5. The magnetic fastener clip of claim 1 wherein the turn couplerfurther comprises a wing.
 6. The magnetic fastener clip of claim 5wherein the key way base includes a tab.
 7. The magnetic fastener clipof claim 1 wherein the magnet does not have a hole.
 8. The magneticfastener clip of claim 1 wherein the key-way base engages a slot on abody panel.
 9. A magnetic fastener clip comprising: a cup having atleast one hole; a cup cover injection molded on an outside portion ofthe cup; an inner ring injection molded on at least part of the cup; amagnet operably inserted into the inner ring; at least one wing attachedto the cup cover; and a key-way base attached to the at least one wingvia a post.
 10. The magnetic fastener clip of claim 9 wherein thekey-way base includes a tab.
 11. The magnetic fastener clip of claim 9wherein the inner ring locates the magnet in the cup at a predetermineddistance from the inner surface of the cup.
 12. The magnetic fastenerclip of claim 9 wherein the at least one hole allows injection moldingof the inner ring.
 13. The magnetic fastener clip of claim 9 wherein thecup has a recess around an outside perimeter of the cup sized to avoidstamping burrs contacting a magnetic attachment surface.
 14. Themagnetic fastener clip of claim 9 wherein the magnet does not have ahole.
 15. The magnetic fastener clip of claim 9 wherein the inner ringis formed by temporarily inserting a core pin such that injectionmaterial forms between an outer portion of the core pin and the cup. 16.The magnetic fastener clip of claim 9 wherein the at least one wing hascurved ends.
 17. The magnetic fastener clip of claim 9 wherein the innerring is sufficiently flexible to permit the magnet to be press fit intothe inner ring.
 18. The magnetic fastener clip of claim 9 wherein amagnetic cup lip is flush with a magnetic attachment surface.
 19. Avehicle and magnetic clip comprising: a vehicle chassis having amagnetic attachment surface; a magnetic fastener clip comprising: a cuphaving at least one hole; a cup cover injection molded on an outsideportion of the cup; an inner ring injection molded on at least part ofthe cup; a magnet operably inserted into the inner ring; and a turncoupler including a key-way base attached to the cup cover.
 20. Thevehicle and magnetic clip of claim 19 wherein the turn coupler furthercomprises at least one wing attached to the key-way base via a post. 21.The vehicle and magnetic clip of claim 20 wherein the at least one wingincludes a tab operative to cause the at least one wing to spring awayfrom the key-way base.
 22. The vehicle and magnetic clip of claim 19wherein the cup has a height to form a gap between the magnet and themagnetic attachment surface.